Molding of optical connectors using a core pin

Abstract

A core pin assembly is provided that includes a core pin insert comprising a core pin body and at least one pin member, and a core pin support defining a passageway for receiving the core pin member. The core pin support, when assembled to the core pin insert, retains the core pin members in desired positions and resists unintended flexing of the core pin members during the molding process. When used to create a lens body, the presence of the core pin support in the mold during the molding process causes formation of a void, or “window,” in the molded lens body. The window of the lens body may be used to advantage in fixing optical fibers to the lens body by applying epoxy within the window directly to the fiber's glass core/cladding, and in close physical proximity to the fibers distal end within the lens body's passageway.

1 . A core pin assembly comprising:
 a core pin insert comprising:
 a core pin body; and 
 at least one axially-elongated core pin member supported on and extending from said core pin body; and 
   a core pin support comprising a rigid body member defining an axially-extending passageway dimensioned to receive said core pin member.   
     
     
         2 . The core pin assembly of  claim 1 , wherein said core pin insert comprises a plurality of axially-elongated core pin members supported on an extending from said core pin body in a spaced parallel relationship, and wherein rigid body member of said core pin support comprises a corresponding plurality of axially-extending passageways in a corresponding spaced parallel relationship, each of said corresponding plurality of axially-extending passageways being dimensioned to receive a respective one of said plurality of core pin members. 
     
     
         3 . The core pin assembly of  claim 1 , wherein said core pin support is assembled to said core pin insert with said core pin member extending through said passageway of said core pin support. 
     
     
         4 . The core pin assembly of  claim 1 , wherein said core pin support is fixed in position relative to said core pin insert such that said core pin member and said passageway extend along a common axis. 
     
     
         5 . A method for manufacturing an optical connector having an axial passageway, the method comprising:
 providing a core pin assembly comprising:
 a core pin insert comprising a core pin body and at least one axially-elongated core pin member supported on and extending from said core pin body; and 
 a core pin support comprising a rigid body member defining an axially-extending passageway dimensioned to receive said core pin member; 
   providing a molding apparatus comprising mold members configured to cooperate with the core pin assembly to define a mold cavity for molding the optical connector;   preparing the mold cavity by assembling the core pin assembly to the mold members and closing the mold members;   introducing moldable material into the mold cavity and around at least portions of the core pin member and the core pin support; and   opening the mold members and withdrawing the optical connector from the mold cavity.   
     
     
         6 . The method of  claim 5 , wherein preparing the mold cavity by assembling the core pin assembly to the mold members and closing the mold members comprises assembling the core pin support to the core pin insert with the core pin member extending through the passageway of the core pin support. 
     
     
         7 . The method of  claim 5 , wherein preparing the mold cavity by assembling the core pin assembly to the mold members and closing the mold members comprises fixing the core pin support and the core pin member in relative positions in which the core pin member and the passageway extend along a common axis. 
     
     
         8 . An optical connector for optically coupling an optoelectronic device with a corresponding optical fiber, connector comprising:
 a lens body of an optically-clear moldable material comprising:
 a lens adapted to focus light along an optical path between an optoelectronic device and an optical fiber; 
 a reflective surface disposed to alter a direction of the optical path; 
 a passageway for supporting at least one optical fiber in alignment with said reflective surface and said lens, said passageway being discontinuous and having a distal end adjacent said reflective surface and a proximal end opposite said distal end, said distal end being separated from said proximal end by a window defined by said lens body. 
   
     
     
         9 . The optical connector of  claim 8 , wherein said optical fiber has a diameter measuring approximately 250 microns, and wherein said passageway has a maximum diameter measuring approximately 300 microns. 
     
     
         10 . A method for manufacturing an optical subassembly, the method comprising:
 providing an optical fiber comprising a glass fiber core, cladding bonded to the glass fiber core, a buffer surrounding said cladding, and a jacket surrounding said buffer;   providing a lens body of an optically-clear moldable material comprising:
 a lens adapted to focus light along an optical path between an optoelectronic device and an optical fiber; 
 a reflective surface disposed to alter a direction of the optical path; and 
 a passageway for supporting at least one optical fiber in alignment with said reflective surface and said lens, said passageway being discontinuous and having a distal end adjacent said reflective surface and a proximal end opposite said distal end, said distal end being separated from said proximal end by a window defined by said lens body; 
   cleaving the optical fiber to remove a portion of the buffer and jacket to expose a portion of the clad glass fiber core;   positioning the cleaved optical fiber through the proximal and distal ends of the passageway of the lens body with a portion of the exposed clad glass fiber core positioned within the window of the lens body; and   applying bonding material within the window to bond the lens body directly to the exposed clad glass fiber core.   
     
     
         11 . The method of  claim 10 , wherein providing a lens body of an optically-clear moldable material comprises:
 providing a core pin assembly comprising:
 a core pin insert comprising a core pin body and at least one axially-elongated core pin member supported on and extending from said core pin body; and 
 a core pin support comprising a rigid body member defining an axially-extending passageway dimensioned to receive said core pin member; 
   providing a molding apparatus comprising mold members configured to cooperate with the core pin assembly to define a mold cavity for molding the optical connector;   preparing the mold cavity by assembling the core pin assembly to the mold members and closing the mold members;   injecting moldable material into the mold cavity and around at least portions of the core pin member and the core pin support; and   opening the mold members and withdrawing the optical connector from the mold cavity.   
     
     
         12 . The method of  claim 11 , wherein preparing the mold cavity by assembling the core pin assembly to the mold members and closing the mold members comprises assembling the core pin support to the core pin insert with the core pin member extending through the passageway of the core pin support. 
     
     
         13 . The method of  claim 11 , wherein preparing the mold cavity by assembling the core pin assembly to the mold members and closing the mold members comprises fixing the core pin support and the core pin member in relative positions in which the core pin member and the passageway extend along a common axis.